Flux cored arc welding electrode

Abstract

A flux cored arc welding electrode of the type used with external shielding gas wherein the electrode comprises an outer ferrous sheath and a particulate fill material comprising an acidic flux system and alloying agents with the fill material including an arc stabilizer, titanium dioxide, calcium fluoride, an alloying system of 0-4.0 percent by weight of electrode selected from the class consisting of aluminum, silicon, titanium, carbon and manganese. Iron powder controls the percentage of the fill of the electrode and 0.2-1.0 percent by weight of electrode is polytetrafluoroethylene powder.

Having defined the invention, preferred embodiments of the invention are claimed as follows: 
     
       1. A flux cored arc welding electrode of the type used with external shielding gas, said electrode comprising an outer ferrous sheath and a particulate fill material comprising an acidic flux system and alloying agents with the fill material having the following constituents: (a) an arc stabilizer;   (b) titanium dioxide;   (c) calcium fluoride;   (d) an alloying system of 0-4.0 percent by weight of electrode selected from the class consisting of aluminum silicon, titanium, carbon and manganese;   (e) iron to control the percentage of fill; and,   (f) 0.2 to 1.0 percent by weight of electrode polytetrafluoroethylene powder.   
     
     
       2. An electrode as defined in claim 1 especially for downhand welding wherein said iron is in an amount causing said percentage of fill in said electrode to be greater than 20%. 
     
     
       3. En electrode as defined in claim 2 wherein said percentage fill is greater than 22%. 
     
     
       4. An electrode as defined in claim 2 wherein said percentage fill is in the range of 20-30%. 
     
     
       5. An electrode as defined in claim 2 wherein said percentage fill is in the range of 22-30%. 
     
     
       6. An electrode as defined in claim 2 with an amount less than 0.02% by weight of said electrode being boron. 
     
     
       7. An electrode as defined in claim 6 wherein said boron is in the form of boron oxide. 
     
     
       8. An electrode as defined in claim 2 wherein said arc stabilizer is in the amount of 0.2-0.5 percent by weight of said electrode. 
     
     
       9. An electrode as defined in claim 2 including aluminum oxide in the range of 0-0.6 percent by weight of said electrode. 
     
     
       10. An electrode as defined in claim 2 including silicon dioxide in the range of 1.0-1.5 percent by weight of said electrode. 
     
     
       11. An electrode as defined in claim 2 modified for out of position welding and including silicon dioxide less than 1.0 percent by weight of said electrode. 
     
     
       12. An electrode as defined in claim 2 wherein said titanium dioxide is in the range of 3.0-6.0 percent by weight of said electrode. 
     
     
       13. An electrode as defined in claim 2 wherein said calcium fluoride is in the range of 0.05 to 0.30 percent by weight of said electrode. 
     
     
       14. An electrode as defined in claim 2 wherein said calcium fluoride is in the range of 0.08 to 0.15 percent by weight of said electrode. 
     
     
       15. An electrode as defined in claim 2 wherein said arc stabilizer is selected from the class consisting of sodium oxide, potassium oxide or combinations thereof. 
     
     
       16. An electrode as defined in claim 2 especially for smaller diameter out-of-position welding wherein said iron is in an amount causing said percentage of fill in said electrode to be 12-18%. 
     
     
       17. An electrode as defined in claimed 1 with an amount less than 0.02% by weight of said electrode being boron. 
     
     
       18. An electrode as defined in claim 17 wherein said boron is in the form of boron oxide. 
     
     
       19. An electrode as defined in claim 18 wherein said boron oxide is in the range of 0 to 0.6 percent by weight of electrode. 
     
     
       20. An electrode as defined in claim 1 wherein said arc stabilizer is selected from the class consisting of sodium oxide, potassium oxide or combinations thereof. 
     
     
       21. An electrode as defined in claim 20 wherein said arc stabilizer is in the amount of 0.2-0.5 percent by weight of said electrode. 
     
     
       22. An electrode as defined in claim 1 wherein said arc stabilizer is in the amount of 0.2-0.5 percent by weight of said electrode. 
     
     
       23. An electrode as defined in claim 1 including aluminum oxide in the range of 0-0.6 percent by weight of said electrode. 
     
     
       24. An electrode as defined in claim 1 including silicon dioxide in the range of 1.0-1.5 percent by weight of said electrode. 
     
     
       25. An electrode as defined in claim 1 modified for out of position welding and including silicon dioxide less than 1.0 percent by weight of said electrode. 
     
     
       26. An electrode as defined in claim 1 wherein said titanium dioxide is in the range of 3.0-6.0 percent by weight of said electrode. 
     
     
       27. An electrode as defined in claim 1 wherein said titanium dioxide is in the range of 4.0-5.0 percent by weight of said electrode. 
     
     
       28. An electrode as defined in claim 1 wherein said calcium fluoride is in the range of 0.05 to 0,30 percent by weight of said electrode. 
     
     
       29. An electrode as defined in claim 1 wherein said calcium fluoride is in the range of 0.08 to 0.15 percent by weight of said electrode. 
     
     
       30. An electrode as defined in claim 1 wherein said iron in said fill material is at least 10 percent by weight of said electrode. 
     
     
       31. An electrode as defined in claim 1 wherein said alloy system includes manganese in the amount of at least 2.0 percent by weight of said electrode. 
     
     
       32. An electrode as defined in claim 1 wherein said alloy system includes aluminum in the amount of less than 1.0 percent by weight of said electrode. 
     
     
       33. An electrode as defined in claim 1 wherein said alloy system includes silicon in the amount of less than 1.0 percent by weight of said electrode. 
     
     
       34. An electrode as defined in claim 1 wherein there is no aluminum. 
     
     
       35. A flux cored arc welding electrode of the type used with external shielding gas, said electrode comprising an outer ferrous sheath and a particulate fill material comprising an acidic flux system and alloying agents with the fill material having the following constituents: (a) an arc stabilizer in the range of 0.2-0.5 percent by weight of said electrode;   (b) titanium dioxide in the range of 3.0-6.0 percent by weight of said electrode;   (c) calcium fluoride in the range of 0.08-0.15 percent by weight of said electrode;   (d) an alloying system of 0-4.0 percent by weight of electrode selected from the class consisting of aluminum silicon, titanium, carbon and manganese;   (e) iron to control the percentage of fill; and,   (f) 0.2 to 1.0 percent by weight of electrode polytetrafluoroethylene powder.   
     
     
       36. An electrode as defined in claim 35 wherein said percentage fill is in the range of 22-30%. 
     
     
       37. An electrode as defined in claim 35 wherein said alloy system includes manganese in the amount of at least 2.0 percent by weight of said electrode. 
     
     
       38. An electrode as defined in claim 35 wherein said alloy system includes aluminum in the amount of less than 1.0 percent by weight of said electrode. 
     
     
       39. An electrode as defined in claim 35 wherein said alloy system includes silicon in the amount of less than 1.0 percent by weight of said electrode. 
     
     
       40. A flux cored arc welding electrode of the type used with external shielding gas, said electrode comprising an outer ferrous sheath and a particulate fill material comprising an acidic flux system with the fill material having the following constituents: (a) an arc stabilizer;   (b) titanium dioxide;   (c) aluminum in the amount of at least 1.10 percent by weight of said electrode; and,   (d) 0.2 to 1.0 percent by weight of electrode polytetrafluoroethylene powder.   
     
     
       41. A flux cored arc welding electrode of the type used with external shielding gas, said electrode comprising an outer ferrous sheath and a particulate fill material comprising an acidic flux system and alloying agents with the fill material having the following constituents: (a) an arc stabilizer;   (b) titanium dioxide;   (c) an alloying system of 0-4.0 percent by weight of electrode selected from the group consisting of aluminum silicon, titanium, carbon and manganese;   (d) iron to control the percentage of fill;   (e) 0.2 to 1.0 percent by weight of electrode polytetrafluoroethylene powder; and   (f) boron.   
     
     
       42. A flux cored arc welding electrode of the type used with external shielding gas, said electrode comprising an outer ferrous sheath and a particulate fill material comprising an acidic flux system and alloying agents with the fill material having the following constituents: (a) an arc stabilizer;   (b) 3.0-12.0 percent by weight of electrode titanium dioxide;   (c) an alloying system of 0-4.0 percent by weight of electrode selected from the class consisting of aluminum silicon, titanium, carbon and manganese;   (d) iron to control the percentage of fill; and   (e) 0.2 to 1.0 percent by weight of electrode polytetrafluoroethylene powder.   
     
     
       43. A flux cored arc welding electrode of the type used with external shielding gas, said electrode comprising an outer ferrous sheath and a particulate fill material comprising an acidic flux system and alloying agents with the fill material having the following constituents: (a) an arc stabilizer selected from the group consisting of sodium compounds and potassium compounds;   (b) titanium dioxide:   (c) an alloying system of 0-4.0 percent by weight of electrode selected from the class consisting of aluminum silicon, titanium, carbon and manganese;   (d) iron to control the percentage of fill; and,   (e) 0.2 to 1.0 percent by weight of electrode polytetrafluoroethylene powder.